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If you have ever visited or worked in an industrial facility, you most probably have seen a lot of electrical and control panels in there.
Usually, most of the Electrical and Control Panels in an industrial plant, are located in one or multiple rooms. But if we explore every nook and cranny of the plant, chances are we discover some other electrical cabinets installed outside of these particular rooms.
In this video, we will learn more about RIO panels and the reasons for locating them around the plant.
In a previous video, we talked a little bit about PLC Control Panels. As you might recall, we put some Input and Output cards on the same rack as the PLC. We have called them Direct Input and Outputs or “Direct IOs” for short. You can also call them Local rack-based IOs.
👉 How an Electrical Control Panel Works (PLC Control Panel Basics) ▶ • How Electrical Control...
Obviously, these Input and Output cards are meant to be connected to the field devices like instruments, valves, and so on. Until 40 or 50 years ago, connecting these IO cards to the end devices at the field was through parallel cabling and using marshaling units and some Junction Boxes (JBs) in between.
This method, however, is still applicable today but has some limitations and disadvantages. For example, if the distance from the main Programmable Logic Controller becomes more than a certain limit there are restrictions for implementation like the risk of voltage drop over the lengthy cables.
Today, with the advancement of industrial communication protocols like Profibus, Fieldbus Foundation, IO-Link, AS-interface, and so on, and of course, with the emergence of technologies like Fiber Optic in data transferring cables, there is a far better method for doing so. Yes, we can use Remote Input Output panels.
In fact, in addition to using the Direct or Local rack-based IOs, we also bring some IO cards to the remote and difficult-to-reach areas across the factory where we have lots of sensors, actuators, and transmitters in there.
After hardwiring these devices to the remote IO modules, by connecting a two-wire Fieldbus communication cable between the PLC and an interface module on the remote IO rack, we will be able to send and receive signals to and from PLC.
Depending on the distance between the PLC panel and the remote IO panel, we have to choose a Fieldbus copper cable or a Fiber Optic cable with some converters in between. So we can bring the data from kilometers away from the main control panel thanks to the fiber optic technology.
Looking for the sensor and actuator accumulation throughout the field and their distance from the main PLC control panel is an essential consideration while designing an industrial automation system. This will help you decide the location of each Remote IO panel.
By using remote I/Os, the amount of cable and the labor we need for cable trays, conduits, and cabling works will be extremely less than conventional methods.
Ultimately, considering all factors, the overall cost is much less in comparison with traditional methods.
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Timestamps of this video:
00:00 Introduction to RIO Panels
00:40 Wiring a Sensor to a PLC Using JBs & Parallel Cabling
02:26 Why to Use a Remote I/O System
03:59 Remote IO System Benefits
04:45 Solutions to Remote IO System Disadvantages
05:44 Are Local Rack-Based I/Os Still Useful?
06:12 Extending Local I/Os of a Programmable Logic Controller
06:59 Extra Points and Quick Review
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